Sleeve-Mounted Valve Assembly for Low-Leakage Exhaust-Gas Lines
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Solution Overview
Problem
Existing valves used for closing exhaust-gas lines in motor vehicles face challenges in achieving low leakage rates due to high production outlay and complex welding processes, which complicate the formation of tight sealing surfaces and positional tolerances.
Innovation Solution
The closing bodies are fixedly arranged on a sleeve that can be slid onto the plunger, allowing for pre-assembly outside the valve housing, reducing the number of fastening processes within the housing and enabling easier and more accessible welding, thus achieving a secure and low-leakage valve connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the closing bodies are fastened directly to the plunger inside the valve housing, then the valve can be assembled, but the welding process becomes highly cumbersome and production outlay increases
Solution Approach 1:
The valve assembly is divided into two main segments: a plunger unit and a closing body unit connected via a connecting piece. This segmentation allows the closing bodies to be pre-assembled and welded outside the housing, avoiding the cumbersome in-housing welding process while maintaining functional integration during operation.
Solution Approach 2:
A connecting piece serves as an intermediary element between the plunger and the closing bodies. This mediator enables the closing bodies to be fastened securely while allowing pre-welding outside the housing, thus simplifying the manufacturing process and reducing production outlay.
2Ease of manufacture
If the closing bodies are positioned deep within the housing, then the valve structure is compact, but access for welding becomes difficult and the welding process is cumbersome
Solution Approach 1:
The closing bodies and connecting piece are pre-assembled and pre-welded outside the valve housing before final installation. This preliminary action allows welding to be performed in an accessible environment, avoiding the difficulty of welding deep within the housing, while the completed assembly is then installed in a space-efficient manner.
3Productivity
If conventional fastening methods are used inside the housing, then the valve can be assembled, but production time increases and productivity decreases
Solution Approach 1:
The connecting piece and closing bodies are pre-assembled and pre-welded outside the housing before final installation. This preliminary preparation eliminates time-consuming fastening operations from the in-housing assembly process, significantly reducing production time and increasing overall productivity.
Solution Approach 2:
By segmenting the assembly into pre-fabricated units (plunger unit and closing body unit), the number of fastening operations required during final assembly is minimized, thereby reducing production time and improving manufacturing efficiency.
4Reliability
If additional sealing surfaces are added to compensate for welding tolerances, then leakage rate decreases, but manufacturing complexity and outlay increase
Solution Approach 1:
The connecting piece and closing bodies are pre-assembled and pre-welded outside the housing under controlled conditions, allowing for better tolerance management. This preliminary fabrication ensures accurate alignment and reduced welding tolerances, minimizing the need for additional compensating sealing surfaces and reducing overall manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production outlay and ensures a low leakage rate while providing a reliable and long-term-stable valve connection by simplifying the fastening processes and allowing for precise tolerance compliance.
Implementation Method 1
the sleeve is pressed together with the plunger
Implementation Method 2
the sleeve is pressed together with the plunger
Implementation Method 3
the closing bodies can be moved into abutment against respective sealing seats
Data Source
AI summary
A valve includes: a drive; a plunger connected to the drive; and two closing bodies connected to the plunger and movable by the plunger such that the two closing bodies are movable into abutment against respective sealing seats or away from the respective sealing seats. The two closing bodies are arranged fixedly on a sleeve, and the sleeve is slidable onto the plunger and connected fixedly to the plunger.